JICA, Manual For Micro-Hydro Power Development

Study on Rural Energy Supply with Utilizatio n of Renewable Energy Manual for Micro-hydro power Development
in Rural Areas in the Republic of Indo nesia Chapter 6
CHAPTER 6 DESIGN FOR MECHANICAL AND

ELECTRICAL STRUCTURES
6.1 Fundamental Structure of Equipment for Power Plant
The fundamental equipment and facilities are briefly shown above and the details of
each kind of equipment and facilities are explained in each clause after clause 6.2.
However, the summary of micro-hydro power generating equipment for rural
electrification is shown hereinafter for easy and quick reference. M ore details shall
continue in the following clause from 6.2.
Summary of Micro-hydro Power Generating Machinery for Rural Electrification

in Indonesia
1. Fundamental Conditions
The following conditions are required and essential for rural electrification in
Indonesia.
1) Stable operation for long term
2) Easy operation by semi-skilled operator(s) or villager(s)
3) Local made machines in Indonesia for easy future maintenance and repair
(except small parts)
4) Cheaper cost of equipment including installation
5) Enough and acceptable technical guarantees of machinery with reliable test data
and supply records
2. Recommendation
According to the above conditions and the survey results on development of
micro-hydro power plant for rural electrification in Indonesia, the following two types
of hydropower generating machine only are recommended by JICA Survey Team at
present stage in Indonesia.
1) Synchronous generator with cross flow type turbine with dummy load and
controller (ELC)
2) Asynchronous generator (induction motor with capacitors) with reverse pump
type turbine with dummy load and controller (IGC)
- 6-1 -
Table 6.1.1 Recommended Micro-hydro Power Generating Equipment

Description Synchronous Generator with Cross Asynchronous Generator with
Flow type Turbine Re ve rse Pump type Turbine (PAT)
Merits & Demerits
Merits *Very reliable power source with stable *Lower cost if a pump with motor
frequency & voltage for independent suitable for site design condition is
network. found.
*Machine suitable to any actual site *Construction of machine is simple.
condition can be designed and
manufactured.
Demerits *A little higher cost than PAT *Difficulty to select a suitable pump
with motor at market
*No control of voltage
* Short life time of capacitors for this
system
Te chnical aspect
Net head Hn 4 50 m 4 - 20 m
Water flow Q 0.1 - 0.8 m 3 /s (Discharge is a little 0.04 - 0.13 m3 /s (discharge shall be
(discharge) variable) kept always constant )
Turbine output at P t 10 250 kW 2 7 kW
turbine shaft P t =0.98 x Hn x Q x t ( t= 0.7) P t =0.98 x Hn x Q x p
(p = t =0.65)
As pump efficiency (p) is too much
variable due to change of discharge,
the pump with induction motor of
nearly same head and same discharge
shall be selected.
Power transmitter Belt coupling for speed matching Direct coupled without transmitter
between turbine and generator
m : Efficiency of transmitter
Dummy load type ELC controller with thyristor IGC controller with transistor
governor
Generator output at Pg 8.5 210 kW 1.5 5.3 kW
generator terminal Pg = P t x g x m (g = 0.88, m =0.97) Pg = Pt x g ( g = 0.75)
(coupled with transmitter)
Rated output of PkVA PkVA > Pg /0.8 (PF= 0.8) The induction motor originally
generator (kVA) to be The generator with rated output of more coupled with the pump shall be used
applied than Pg /0.8 shall be selected. as induction generator by adding
separate capacitors
Rotation speed 1500 rpm 1515 1525 rpm due to speed of
induction motor as generator
Voltage 380/220V, star connection 380/220V, star connection
Stable with AVR on generator Voltage control cannot be made
without AVR
Frequency 50 Hz, Stable 50.5 50.75 Hz Not so stable
Dummy Pd Air heaters (Pd = Pg x SF), SF=1.3 Air heaters (Pd = Pg x SF), SF=1.3
Inlet valve Butterfly valve (It is not provided for Same as left, but it is neglected in
cost saving sometimes, but its better to case of small capacity.
be provided for complete stop of
turbine)
Note: t, m, g and SF are fixed only for bri ef checking. In case of detail design, it is recommended to check the
efficiency of each machine and facility.
- 6-2 -
The following equipment and facilities are to be required as fundamental structure for
the power plant, details of which are shown in Table 6.1.2
Equipment & Facility Purpose & Function

1.Inlet valve: To control the stop or supply of water to turbine from
penstock.
2.Water turbine: To change the energy of water to the rotating power.
3.Governor of turbine: To control the speed and output of turbine
4.Power transmission facility: To transmit the rotation power of turbine to generator.
5.Generator: To generate the electricity from turbine or its transmitter
6.Control and protection panel: To control and protect the above facilities for safe operation
7.Switchgear (with transformer): To control on/off operation of electric power and step-up the
voltage of transmission lines (if required)
Note: The above items 3, 6 & 7 may sometimes be combined in one panel as a sort of equipment
in case of micro power plant.
Table 6.1.2 Composition of Fundamental Equipment for Hydraulic Power Station

Equipment Type Control Method
Inlet valve Butterfly valve Hand operat ed type
Bi-plane butterfly valve Motor operated type
Sluice valve Counter weight type
Needle valve
Turbine Cross flow Dummy load type
Reverse Pump Oil pressure type
H-shaft Pelton Motor operated type
Turgo-Pelton Manual operated type
Propeller Non-controlled type
H-shaft Francis
Tubular
Power transmission Fixed coupling
facility (Speed increaser) Flexible coupling
Belt coupling
Gear coupling
Generator Synchronous Manual
Induction AVR
Self-excitation Induction APFR
Control & Protection Wall mounted Control switches,
panels Self stand open type Main switches
Self stand sealed type IC panels
Relays
Power Transformer Oil immersed, self cooling,
single or 3-phase, pole
trans former
- 6-3 -
Discharge Q [l/s]
Figure 6.1.2 (a) Applicable of Crossflow and PAT at Turbine

100
50
20
Ne t Head (m)
10
7 kW
6 kW
5 kW
4 kW
2 kW 3 kW
4
1
40 50 60 70 80 90 100 110 120 130 140
Disc harge (l/s)
Figure 6.1.2 (b) Applicable limit of PAT at Turbine Shaft (in Indonesia at present stage)
- 6-4 -
6.2 Turbine (Water turbine)
6.2.1 Type and Output of Water Turbine
Water turbines are mainly classified into two types with some additional
classification as follows:
1 Impulse turbine Pelton turbine
Crossflow turbine
Turgo-impluse turbine
2 Reaction turbine Francis turbine
Propeller turbine Kaplan turbine
Diagonal mixed flow
Tubular turbine
Straight flow turbine (package type)
Note:
1) Impulse turbine: Turbine construction that rotates the runner by the impulse of a
water jet having the velocity head which has been converted
from the pressure head at the time of jetting from the nozzle.
2) Reaction turbine: Turbine construction that rotates the runner by the pressure
head of flow.
Shaft arrangement: The arrangement of turbines will be also classified into two
types, i.e. horizontal shaft (H-shaft) and vertical shaft
(V-shaft)
Referring to the required output, available net head and water flow (discharge), the
following types of turbine may be applicable for micro or small hydraulic power
plant in rural electrification.
(1) Horizontal Pelton turbine
(2) Horizontal Francis turbine
(3) Cross flow turbine
(4) Tubular turbine S-type tubular turbine
Vertical tubular turbine
Runner rotor integrated turbine
Vertical propeller turbine
Horizontal propeller turbine
- 6-5 -
(5) Turgo impulse turbine

(6) Reverse pump turbine Vertical propeller type
Horizontal propeller type
Submerged pump type
The output of turbine is calculated with following formula:

Pmax = 9.8 x He x Qmax x t
Pmax : M aximum output (kW)
He : Net head (m)
Qmax : M aximum discharge (m3/s)
t : M aximum turbine efficiency (%) Please refer to chapter 6.2.2
The brief characteristics, explanation and drawing of each type are shown in Table 6.2.1.
The applicable range of each type of turbine is shown in Figure 6.2.1.
Referring to this table and figure, the customer can select the type of turbine, which is
most suitable to the actual site condition including the total cost of civil work and
equipment.
At present, however, it is recommended to apply cross flow turbine, which is designed
and manufactured in Indonesia, because the proper design of cross flow turbine can be
achieved by applying available model test data and the cost is comparably low.
The reverse pump may also be used as reverse pump turbine by reversing the direction
of rotation, if the characteristics of water pump, which is available in market, is matched
almost strictly to those of the turbine required from the site condition (head, water
discharge, output, efficiency, rotation speed etc.).
However, as the site condition of each power plant is not always the same and the
matching of characteristics of pump and proposed turbine is difficult, the selection of
standard pump for turbine shall be made carefully and circumspectly. In case the
characteristics are well matched between pump and turbine, the application of reverse
pump turbine is recommended and the cost of such machine will be cheaper.
In future the other types of turbine will be selected widely because other type turbines
may also be manufactured with proper design and fabrication ability in Indonesia in the
near future.
- 6-6 -
Figure 6.2.1 Applicable Type (Selection) of Turbines
- 6-7 -
6.2.2 S pecific S peed and Rotational S peed of Turbine
The specific speed is the ratio between the rotational speed of two runners geometrically
similar to each other, which derived from the conditions of the laws of similarity, and
specific speed of similar runners in a group by the rotational speed obtained when one
runner has effective head H = 1m and output P = 1kW.
It may be understood that the specific speed is a numerical value expressing the
classification of runners correlated by three factors of effective head, turbine output and
rotational speed as follows:
1/2 5/4
Ns = (N x P )/ H N = (Ns x H5/4 )/ P1/2
Where, Ns; Specific speed (m-kw)
N; Rotational speed of turbine (rpm)
P; Output of turbine (kW) = 9.8 x Q x H x
H; Effective head (m)
3
Q; Discharge (m /s)
; M aximum efficiency (%, but a decimal is used in calculations)
= 82 % for Pelton turbine
= 84 % for Francis turbine
= 77 % for cross flow turbine*
= 84 % for S-type tubular turbine
Note: * 70% should be applied for cross flow type turbines in Indonesia at present
because the efficiency of present turbines in Indonesia is not so high due to
fabrication quality.
The specific speed of each turbine is specified and ranged according to the construction
of each type on the basis of experiments and actual proven examples.
The limitation of specific speed of turbine (Ns-max) can be checked in the following
formula.
-0.243
Pelton turbine: Ns-max 85.49H
-0.5
Cross flow turbine: Ns-max 650H
Francis turbine: Ns-max (20000/(H+20))+30
Horizontal Francis turbine: Ns-max 3200H-2/3
Propeller turbine: Ns-max (20000/(H+20))+50
Tubular turbine Ns-max (20000/(H+16))
The range of specific speed of turbine is also shown in Figure 6.2.2
- 6-8 -
Specific speed (m-kW)

0 200 400 600 800 1000
Pelton turbine 1 2 Ns 25
Francis turbine 60 Ns 300
Cross flow turbine 40 Ns 200
Propeller turbine 250 Ns 1000
Figure 6.2.2 Range of specific speed by turbine type
- 6-9 -
Table 6.2.1 Kinds and Characteristics for each Type of Water Turbine page 1
- 6-10 -
Table 6.2.1 Kinds and Characteristics for each Type of Water Turbine page 2
- 6-11 -
6.2.3 Design of Cross Flow Turbine

Brief design of cross flow turbines T-13 and T-14, which are designed and
manufactured in Indonesia according to the proper design data, is shown hereunder. The
detailed design shall be referred to from the manufacturers design sheet. The design
shall be conducted in the following procedure:
Basic data of T-13 and 14 are available from the model test.
Diameter of turbine: 300mm No. of runner blades: 28nos. Unit speed: 133 rpm
3
1 To get the basic data for rated water flow (m /s), elevations (m) of water level at
forebay and turbine center (or tailrace water if designed as special case) from civil
design.
2 To calculate net head from gross head by deducting head loss of penstock (friction
and turbulence).
3 To calculate the net hydraulic power and turbine shaft output from water flow, net
head and turbine efficiency.
4 To calculate width of turbine runner according to manufacturers recommendation.
5 To calculate the mechanical power to generator from efficiency of power
transmitter (speed increaser)
6 To calculate rated electrical output of generator (kW). ---- M aximum output of
electricity
7 To calculate the rotational speed of turbine from specific speed, turbine shaft
output (Item 3) and net head.
8 To select suitable generator available at market and its output (kVA), frequency,
voltage, power factor and rotational speed (frequency), referring to catalogue of
generator manufacturer.
9 To calculate the ratio of rated rotational speed of turbine and generator.
10 To select the width and length of belt referring to belt manufacturers
recommendation.
11 To calculate the capacity of dummy load and suitable ELC (Electronic Load
Controller) or IGC(Induction Generator Control) in case of induction generator.
12 To calculate the diameters of pulley of turbine and generator.
For detailed design, refer to Design M anual for Cross Flow type Turbine attached
hereinafter.
- 6-12 -
6.2.4 Design of Reverse Pump Type Turbine (Pump As Turbine)
As a water pump is to be used as turbine by reversing rotation of pump, the selection of

type of pump is very important.
1 To calculate and get the effective head (net head), water flow (discharge), and
net hydraulic power using the same method as item 1, 2 and 3 of the above cross
flow turbine in Chapter 6.2.3.
2 To check a suitable pump is available in the market, considering the maximum
efficiency point of pump, rotation speed of motor (generator: 2, 4 or 6 poles)
because the direct coupling between turbine and generator is usually adopted for
this kind of turbine. See Table 6.3.1 for the rotation speed. In case of induction
generator, the speed of turbine shall be a little higher (i.e. 2 - 5 %) than that of
generator at rated frequency. (1,550 rpm from 1,500 rpm)
3 To select and finalize the pump as turbine, referring to maximum efficiency
point of pump, applicable efficiency for actual output of turbine shaft because
the range of high efficiency point of pump is very narrow.
4 See the Design M anual for Reverse Pump Turbine for the selection method.
- 6-13 -
6.3 Generator
6.3.1 Type of Generator
Two kinds of generator can be adopted for generating the electric power from energy of
water turbine.
1. Fundamental classification of AC generator

(DC generator is not used usually for power plant)
(1) Synchronous generator Independent exciter of rotor is provided for each unit
Applicable for both independent and existing power
network
(2) Induction generator No exciter of rotor is provided (squirrel cage type)
(Asynchronous) Usually applicable for network with other power source.
Sometimes applicable for independent network with
additional capacitors for less than 25 kW but not so
recommendable for independent network due to difficulty
of voltage control and lifetime of capacitors except cost
saving.
Shaft arrangement Either vertical shaft or horizontal shaft is applied to both
type of above generators.
(M ainly horizontal high-speed type in case of micro/small
plant except reverse pump turbine)
2. Another classification is also applied to AC generators as follows;
1) Three-phase generator Star () connection For 3 phase 4 wire network

Delta() connection For single phase 2 wire network
2) Single-phase generator This type is not used in power network system because
it is difficult to purchase the generator with capacity of
more than 2kW in market. In this case three-phase
generator with delta connection is applied as shown
above.
- 6-14 -
The winding connections of generator (Star and Delta) are shown in Figure 6.3.1 as
follows
R R
each winding
S
S
T T
Star connection Star connection
Figure 6.3.1 Connection Diagram of Generator
The characteristic (advantage & disadvantage) of both type generators is shown in Table
6.3.1.
Table 6.3.1 Comparison of Synchronous Generator and Induction Generator
I. Advantage of Synchronous generator

Item Synchronous generator Induction generator
Independent operation Independent operation is possible
No independent operation is possible
since excitation from other system is
required
Power factor adjustment Operation at desired power factor in Operation power factor is governed
response load factor is possible by generator output and cannot be
adjustable
Excitation current DC exciter is employed. The lagging current is taken as the
exciting current from the system so
that the power factor of the system
decreases. The exciting current
increases in low speed machines.
Voltage and frequency Adjustment is possible as desired in Voltage and frequency
adjustment independent operation adjustment is not possible. The
generator is governed by the
voltage and frequency of the
system.
Synchronizing current Transient current and voltage drop Connection to the system to be made
in the system are small since the by forced paralleling by which a large
paralleling is made after current is created, resulting in a
synchronization. voltage drop in the system.
- 6-15 -
II. Advantage of Induction generator

Item Synchronous generator Induction generator
Construction The rotor has exciting winding The rotor is the same as a
outside the damper winding synchronous generator but the
which is equivalent to the bars rotor is of the squirrel cage type.
of squirrel-cage of induction Thus, the construction is simple
generator. This is more and sturdy. It can easily
complicated correspond to operation under
adverse conditions and is the best
suited for small or medium
capacity.
Exciter and field Required This is not required since
regulator exciting current is taken from the
system
Synchronization Required. Thus, synchronism No synchronizing device is
detector is necessary required since forced paralleling
is made. Rotating speed is
detected and making is
performed almost at synchronous
speed.
Stability Pull out may be occur if the Stable and no pull out due to
load fluctuates suddenly load fluctuation
High harmonic load Allowable output is required Heat capacity of rotor bars is
by the thermal capacity of the large and they are relatively
surface of the magnetic pole strong against higher harmonic
when there is no damper when load
there is a damper
M aintenance In addition to the items for M aintenance is required for
induction generator, stator, cooler and filter but not
maintenance and inspection is required for the rotor of
required for field windings and squirrel-cage type.
brushes if employed.
6.3.2 Output of Generator
The output of generator is shown with kVA and calculated with following formula:
Pg (kVA) = (9.8 x H x Q x ) / pf
Where; Pg; Required output (kVA)
H; Net head (m)
3
Q; Rated discharge (m /s)
- 6-16 -
; Combined efficiency of turbine, transmitter & generator (%)

= turbine efficiency (t) x transmitter efficiency (m ) x generator
efficiency (g)
pf; Power factor ( % or decimal), this figure is decided from kind of
load in network. If inductive load, such as electric motor, low
power factor lamps, is much in network, the figure becomes low i.e.
the generator capacity should be larger according to above formula.
However, 80% is usually applied for convenient purpose of
selection.
In case of micro-hydro power plant, the rated output of generator is selected from the
standard output (kVA) with allowance from the manufacturers catalogue in the market.
6.3.3 S peed and number of poles of generator
The rated rotational speed is specified according to the frequency (50 or 60 Hz) of
power network and the number of poles as shown in following formula
For synchronous generator

P (nos.) = 120 x f / N0 N0 (rpm) = 120 x f / P
Where, P: Number of poles (nos.)
N0: Rated rotational speed (rpm)
f : Frequency of network (Hz), In Indonesia 50Hz is standard
For induction generator
The speed is a little higher than that of synchronous generator for excitation with slip.
N (rpm) = (1-S) x N0
Where, N: Actual speed of induction generator
S: Slip (normally S= -0.02)
N0: Rated rotation speed
As the rotational speed is fixed with number of poles, the speed and pole number of
generator are shown in Table 6.3.1 hereunder. As the frequency in Indonesia is 50 Hz,
the speed shall be selected from 50Hz in the table.
- 6-17 -
Table 6.3.1
Standard Rotational Speed of Generator
Unit: rpm (min-1)
No. of pole 50Hz 60Hz No. of pole 50Hz 60Hz
4 1,500 1,800 14 429 514
6 1,000 1,200 16 375 450
8 750 900 18 333 400
10 600 720 20 300 360
12 500 600 24 250 300
Note: As the frequency in Indonesia is 50 Hz, the speed of 50Hz shall be
selected from the table. The size and cost of higher speed generator is
smaller and cheaper respectively than that of slow speed one.
Referring to the original turbine speed and the rated generator speed, either direct
coupling or indirect coupling with power transmission facility (gear or belt) is selected
so that the suitable ratio of speed between turbine and generator can be matched. The
total cost of turbine, transmitter and generator shall also be taken into consideration. For
micro power plant, 4 8 poles are selected to save the cost
- 6-18 -
6.4 Power transmission facility (S peed Increaser)
There are two ways for coupling between turbine and generator. One is a direct coupling
with turbine shaft and generator shaft. The other is indirect coupling by using power
transmission facility (speed increaser) between turbine shaft and generator shaft.
Rated turbine speed is to be fixed by the selected type of turbine and its original design
condition of net head and water flow (discharge) and can not be changed. On the other
hand, generator speed is to be selected from frequency as shown in the above table.
Therefore, if the speeds of both turbine and generator are completely the same, turbine
and generator can be coupled directly. However, such design of direct coupling is
sometimes not applicable due to high cost of turbine and generator, especially in case of
micro or small power plant. Therefore, the power transmission facility (speed increaser)
is adopted usually in order to match the speed of turbine and generator and save on total
cost
Two kinds of speed increaser are adopted for coupling turbine and generator as follows
1. Gear box type: Turbine shaft and generator shaft are coupled with parallel shaft
helical gears in one box with anti-friction bearing according to the
ratio of speed between turbine and generator. The lifetime is long but
the cost is relatively high. (Efficiency: 97 95% subject to the type)
2. Belt type: Turbine shaft and generator shaft are coupled with pulleys (flywheels)
and belt according to the ratio of speed between turbine and generator.
The cost is relatively low but lifetime is short. (Efficiency: 98 95%
subject to the type of belt)
In case of micro-hydro power plant, V-belt or flat belt type coupling is adopted usually
to save the cost because gear type transmitter is very expensive
- 6-19 -
6.5 Control Facility of Turbine and Generator
6.5.1 S peed Governor
The speed governor is adopted to keep the turbine speed constant because the speed
always fluctuates according to change of load and water head and water flow. The
change of generator rotational speed results in fluctuation of frequency. The governor
consists of speed detector, controller and operation. There are two kinds of governor to
control water flow (discharge) through turbine by operation of guide vane or to control
the balance of load by interchanging of actual and dummy load as follows:
1. Mechanical type: To control water discharge always with automatic operation of guide
vane(s) according to actual load. There are following two types.
Pressure oil operating type of guide vane(s)
Motor operating type of guide vane(s)
2. Dummy load type: To control the balancing of both current of actual load and dummy
load by thyristor i.e. to keep the summation of both actual and
dummy load constant always for the same output and speed of
generator.
The speed detection is made by PG (Pulse Generator), PMG (Permanent M agnet
Generator) or generator frequency.
In case of the mechanical type, many ancillary equipments, such as servomotor of guide
vane, pressure pump, pressure tank, sump tank, piping etc. or electric motor operating
guide vane with control system are required. It means the cost of power plant increases
a lot for such ancillary equipment.
In case of motor operating type, power source, motor and operating mechanism are also
required. Therefore, in case of micro hydro-plant the dummy load type governor is
cheaper and recommended.
Dummy load type governor can be controlled by IGC (Induction Generator Controller)
or ELC (Electronic Load Controller), which have been developed and fabricated in
Indonesia and have a supply record for more than 30 power plants. Two types of
dummy load are adopted with heaters of air cooling and water cooling. In Indonesia, the
air cooling method is usually applied instead of water cooling type due to life time and
simple construction of heater.
- 6-20 -
The capacity of dummy is calculated as follows:

Pd (kW) = Pg (kVA) x pf (decimal) x SF
Where Pd: Capacity of dummy load (Unity load: kW)
Pg: Rated output of generator (KVA)
pf: Rated power factor of generator (%, a decimal is used for
calculation)
SF: Safety factor according to cooling method (1.2 1.4 times of
generator output in kW) in order to avoid over-heat of the heater
according to climate
Note: M aximum output of turbine (kW) may be applied instead of Pg
(kVA) x pf (decimal) because maximum generator output is limited
by turbine output even if the generator with larger capacity is
adopted.
6.5.2 Exciter of generator
In case of synchronous generator an exciter is necessary for supplying field current to

generator and keeping the output voltage constant even if the load is fluctuated.
Various kinds of exciter are available, but at present two kinds of exciter are adopted
mainly as follows:
1. Brush type: Direct thyristor excitation method. DC current for field coil is
supplied through slip ring from thyristor with excitation
transformer.
2. Brush-less type: Basic circuit cons ists of an AC exciter directly coupled to main
generator, a rotary rectifier and separately provided thyristor
type automatic voltage regulator (AVR).
The typical wiring diagrams for both brush type and brush-less type are shown in Figure
6.5.1 and 6.5.2 as follows:
- 6-21 -
PT
Pulse
AVR Generator
CT
(Spee d Dete cto r)
Ex. Tr
Slip ring
Figure 6.5.1 Wiring diagram of brush type exciter
PT
Pul se
AVR Generator
CT
(Spee d De tec tor)
Ex. Tr
Rotating section
DC100V
AC
G
Ex
Figure 6.5.2 Wiring diagram of brush-less type exciter
For micro-hydro power plant the brush-less type is used mainly due to easy
maintenance and the generator with brush-less type is available in Indonesia. Therefore,
this type is recommended.
- 6-22 -
6.5.3 Single Line Diagram

The typical single diagram for both plants with 380/220V and 20kV distribution line are
shown in Figure 6.5.3 and 6.5.4.
Magnet
Contactor NFB Fuse
A x3 To Custmer
x3
Lamp
V Indicator
Hz V
x3
Turbine
H
ELC
G (wit h Hz Relay) Dummy Load
Tr ansmi tter Generator
if requi red
Figure 6.5.3 Single Line diagram of Power Plant with Low Tension Distribution Line
Magnet M. Transformer
Contactor 380V/20kV Disconnection
NFB Fuse
Switch
Circuit
A x3 Breaker
x3
Lamp or Fuse
V Indicator Switch
Hz V
Turbine x3
H
G ELC
(wi th Hz Relay) Dumm y Load
Transmi tter Generator
if required
Figure 6.5.4 Single Line diagram of Power Plant with 20kV Distribution Line
- 6-23 -
6.6 Control, Instrumentation and Protection of Plant
The general evaluation of those potential sites extracted by the above-described study is
then conducted from the viewpoints described below to examine their suitability for
hydropower development.
6.6.1 Control Method of Plant
There are many control methods for power plant, such as supervisory control, operation
control and output control
1. Supervisory control method is classified into continuous supervisory, remote
continuous control and occasional control.
2. Operational control method is classified into manual control, one-man control and
full automatic control.
3. Output control method is classified into output by governor only for independent
network, and water level controlled, discharge controlled and program controlled
for parallel operation with other power sources.
However, in case of micro power plant for independent network in rural electrification,
the occasional control, manual control and governor control with dummy load is usually
adopted because no person can attend the plant full time and the cost of equipment is
saved. It means that any operator attends occasionally to start and stop the plant and the
machine is operated by governor control and when some trouble occurs the operator
inspects the plant to take some necessary measure.
6.6.2 Instrumentation of Plant
Though much instrumentation is considered for supervision of the hydro power plant
during operation, the following instruments shall be furnished as minimum requirement
for micro power plant in rural electrification.
1. Pressure gage for penstock

2. Voltmeter with change-over switch for output voltage
3. Voltmeter with change-over switch for output of dummy load (ballast)
4. Ammeter with change-over switch for ampere of generator output
5. Frequency meter for rotational speed of generator
- 6-24 -
6. Hour meter for operation time

7. KWH (kW hour) meter and KVH (Kvar hour) meter, which is recommended in
order to check and summarize total energy produced by the power plant if there is
some allowance in budget
6.6.3 Protection of Plant and 380/220V Distribution Line
Considering the same reason mentioned for cost saving in instrumentation, the
following protection is required as minimum protection for micro power plant in rural
electrification.
1. Over speed of turbine and generator (detected by frequency)

2. Under voltage
3. Over voltage
4. Over current by NFB (No Fuse Breaker) or M CCB (M olded Case Circuit Breaker)
for low tension circuit.
When above item 1, 2 and 3 are detected by IGC or ELC (adjustable by screw), M C
(M agnet Contactor) operates and trips the main circuit of generator
6.6.4 Protection of 20kV Distribution Line
Normal protection system of line (pole mounted type lighting arresters and fuses or fuse
switches) is to be provided throughout the line. However, the following two kinds of
system are to be installed as protection of 20kV outgoing facility at power station.
1. The following facilities are to be installed at 20kV switchgear of power station in

case 20kV switchgear for large capacity and long outgoing line is required.
1) 1 no. 24kV circuit breaker, driven by AC operated closing and tripping
system of capacitor trip power supply device (3-phase, 200A for
MHP )
2) 3 nos. 24kV fuse switches with fuse, hand operated type (3-phase)
3) 1 no. 24kV earthing switch, hand operated type (3-phase gang operated)
4) 3 nos. 20kV lightning arrester (more than 27kV, 5kA)
5) 1 no. 20 kV voltage transformer(3 phase, 22kV/110V )
- 6-25 -
6) 3 nos. 20kV current transformer (1-phase, ratio to be fixed by the actual

capacity of MHP)
7) 1 set 20kV bus bar system
8) 1 no. Control and protection panel
In case 20kV cubicle is applied, all the above facilities are to be installed in the
cubicle.
2. The following facilities only are to be installed by connection from 20kV terminal
of 20kV/380V transformer on the terminal pole at power plant, in case only
20kV/380V transformer is installed for step-up purpose due to small capacity
distribution line. In this case, protection panel for 20kV line is not required.
1) 3 nos. 24kV fuse switches with fuse, hand operated type (3-phase)
2) 3 nos. 20kV lightning arrester (more than 27kV, 5kA)
3) 1 lot 20kV line connection materials (insulators, support structure, wires)
- 6-26 -
6.7 Inlet valve
Referring to water quantity and head of plant, suitable inlet valve is applied between
penstock and turbine for tight stopping of water supply for safety and maintenance.
However, it may sometimes be omitted for purpose of cost saving in case of low head
power plant if the stop log or gate at forebay can almost stop the water leakage from
forebay into penstock or separate discharge pass-way is provided at forebay
The inlet valve for micro and small power plant is classified into three (3) kinds as
follows:
Type Applicable head Applicable diameter Head loss Leakage

1.Butterfly valve; Not exceeding 200m M edium (up to 2.5m) M edium M edium
2.Bi-plane valve; Not exceeding 350m M ore than 500mmm Little M edium
3.Sluice valve; Exceeding 200m Small Almost zero Very less
M ore details are shown in Table 6.7.1.

For micro or small power plant, butterfly valve is adopted due to simple construction
and low cost.
- 6-27 -
Kinds and Characteristics for Each Type of Inlet Valve

Table 6.7.1
- 6-28 -

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Study on Rural Energy Supply with Utilizatio n of Renewable Energy Manual for Micro-hydro power Development

in Rural Areas in the Republic of Indo nesia Chapter 6

CHAPTER 6 DESIGN FOR MECHANICAL AND

6.1 Fundamental Structure of Equipment for Power Plant

Summary of Micro-hydro Power Generating Machinery for Rural Electrification

Table 6.1.1 Recommended Micro-hydro Power Generating Equipment

Equipment & Facility Purpose & Function

Table 6.1.2 Composition of Fundamental Equipment for Hydraulic Power Station

Figure 6.1.2 (a) Applicable of Crossflow and PAT at Turbine

6.2 Turbine (Water turbine)

6.2.1 Type and Output of Water Turbine

(5) Turgo impulse turbine

The output of turbine is calculated with following formula:

Figure 6.2.1 Applicable Type (Selection) of Turbines

6.2.2 S pecific S peed and Rotational S peed of Turbine

The range of specific speed of turbine is also shown in Figure 6.2.2

Specific speed (m-kW)

Francis turbine 60 Ns 300

Cross flow turbine 40 Ns 200

Propeller turbine 250 Ns 1000

Figure 6.2.2 Range of specific speed by turbine type

6.2.3 Design of Cross Flow Turbine

6.2.4 Design of Reverse Pump Type Turbine (Pump As Turbine)

As a water pump is to be used as turbine by reversing rotation of pump, the selection of

6.3.1 Type of Generator

1. Fundamental classification of AC generator

2. Another classification is also applied to AC generators as follows;

1) Three-phase generator Star () connection For 3 phase 4 wire network

Figure 6.3.1 Connection Diagram of Generator

Table 6.3.1 Comparison of Synchronous Generator and Induction Generator

I. Advantage of Synchronous generator

II. Advantage of Induction generator

6.3.2 Output of Generator

; Combined efficiency of turbine, transmitter & generator (%)

6.3.3 S peed and number of poles of generator

For synchronous generator

6.4 Power transmission facility (S peed Increaser)

6.5 Control Facility of Turbine and Generator

6.5.1 S peed Governor

The capacity of dummy is calculated as follows:

6.5.2 Exciter of generator

In case of synchronous generator an exciter is necessary for supplying field current to

Figure 6.5.1 Wiring diagram of brush type exciter

Figure 6.5.2 Wiring diagram of brush-less type exciter

6.5.3 Single Line Diagram

6.6 Control, Instrumentation and Protection of Plant

6.6.1 Control Method of Plant

6.6.2 Instrumentation of Plant

1. Pressure gage for penstock

6. Hour meter for operation time

6.6.3 Protection of Plant and 380/220V Distribution Line

1. Over speed of turbine and generator (detected by frequency)

6.6.4 Protection of 20kV Distribution Line

1. The following facilities are to be installed at 20kV switchgear of power station in

6) 3 nos. 20kV current transformer (1-phase, ratio to be fixed by the actual

6.7 Inlet valve

Type Applicable head Applicable diameter Head loss Leakage

M ore details are shown in Table 6.7.1.

Kinds and Characteristics for Each Type of Inlet Valve

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